What Are Validated Dental 3D Printing Workflows?
Validated dental 3D printing workflows are material- and printer-specific protocols — covering file preparation, print settings, washing, and curing — that have been tested and approved by the material manufacturer to ensure consistent quality, dimensional accuracy, and biocompatibility for clinical use. Without a validated workflow, even the correct printer and resin cannot guarantee safe or reproducible results.
How One Dental Technician Became an Expert in 3D Printing – Meeting Stefan Schüller
As Senior Application Expert at DETAX GmbH, Stefan Schüller uses his unique background to bridge the gap between material science and practical application, helping dental practices and laboratories navigate the complexities of validated workflows and biocompatible materials.
What makes Schüller particularly effective at this is his background. He’s both a certified dental technician and someone who’s been deep in 3D printing since 2014. That combination is rare, and it gives him insight into both the technical and practical sides of dental 3D printing.
How did you get into dental 3D printing?
Stefan’s journey into dental 3D printing took an interesting route. Starting as a certified dental technician, he found his way into the world of additive manufacturing through an unexpected door: ear mold production.
Stefan Schüller
I worked in an ear mold lab after my training, where I first came into intensive contact with additive manufacturing back in 2014. This allowed me to build up a foundation in 3D printing at an early stage. Thanks to my practical experience in both areas, I have a thorough understanding of the processes, challenges, and requirements of our customers. It’s precisely this combination that enables me to represent Detax optimally as an application expert and support our customers and technology partners like Rapid Shape in a practical manner.
Why does collaboration between material and printer manufacturers matter?
Stefan has witnessed firsthand the evolution of the relationship between material manufacturers and printer companies. His connection with Rapid Shape dates back to those early days in the earmold lab.
Stefan Schüller
Even back then, it was clear how important close coordination between the material and the printing system is for stable processes. Today, we benefit from powerful, highly reproducible printing systems and close technical exchange. With Rapid Shape’s technical expertise and our material expertise at Detax, we can achieve a lot together and create practical solutions for our customers.
What’s the biggest mistake people make about biocompatibility?
After years of working with dental practices and labs, Schüller has identified a dangerous assumption that many newcomers make.
Stefan Schüller
People often assume that biocompatible resins with proven biocompatibility and a classification as a medical device can be used without further considerations outside their specified intended medical purpose. But remember: a material is only considered a medical device and is safe to use if it has been processed in accordance with the manufacturer’s instructions and is used within its approved intended medical purpose.
Where do things typically go wrong in the workflow?
Post-processing is where many practices unknowingly compromise the safety and quality of their 3D-printed devices.
Stefan Schüller
Post-processing — including validated washing and curing — is a central part of the validated workflow because it directly determines the safety and functionality of the end product. As a manufacturer, we at Detax not only deliver the medical device, but also a fully validated workflow. If cleaning and post-curing are not carried out according to this workflow, it can lead to incomplete polymerization, insufficient mechanical properties, or chemical residues. It is therefore essential that users consistently adhere to the validated workflow specified by Detax.
How do you see dental practices and laboratories evolving in their approach to workflow validation?
The regulatory landscape is changing, and Schüller sees this as a positive development for the industry.
Stefan Schüller
Under the MDR, dental practices and labs have to make their processes more transparent and use clearly validated workflows. This means that validation is less of an option and more of a necessity for quality management. This means that standardized, end-to-end workflows specified by the manufacturer will become increasingly important to ensure that everything is secure, efficient, and compliant.
What advice would you give to dental practices or laboratories just starting with validated 3D printing workflows?
Stefan Schüller
For dental practices and labs, it is important to seek comprehensive advice before investing in 3D printing and not to rush into choosing the printer that appears to be the fastest or cheapest.
Key questions should be clarified at an early stage, such as whether an open or closed system better suits your requirements. It is also inadvisable to use hobby 3D printers whose technical and regulatory suitability is not commensurate with the medical device to be manufactured.
Only once the applications and objectives have been clearly defined should the appropriate printing system be selected. In addition, it is essential to consistently adhere to the processes specified and validated by the manufacturer from the outset.
I recommend training the team at an early stage in order to develop a common understanding of 3D printing, the printer, the materials, and the relevant workflows.
What’s the biggest obstacle dental professionals face when transitioning to validated workflows?
Stefan Schüller
I think a big hurdle is the lack of experience in using validated 3D printing workflows. Many dentists can quickly feel uncertain about the technical implementation, especially when it comes to selecting suitable (3D printing) systems, materials, and the correct post-processing, and therefore hesitate to get started.
The solution lies in partnering with 3D printer manufacturers who provide comprehensive validation of documentation, training, and ongoing technical support.
Where do you see the future of dental 3D printing headed?
Stefan Schüller
I believe that the greatest opportunities for dental 3D printing lie in the ability to produce cost-effective dental prostheses within a very short time, using relatively less equipment and personnel.
This can make it easier for socially disadvantaged people in Germany, but also in poorer regions around the world, to access high-quality dental care and regain their quality of life.
The seamless collaboration between equipment manufacturers such as Rapid Shape and material manufacturers such as Detax will save significant time and effort in the future and further increase efficiency in dental practices and laboratories.
The combination of validated workflows, reliable equipment, and accessible materials is making dental 3D printing more approachable than ever.
Would you like to read more about validated workflows in dental 3D printing?
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